Waterproof electrical connector

Abstract: The present invention is directed to an open-face waterproof, underwater matable electrical connector which can be used in marine seismic operations. The male receptacle (3) is of a one-piece construction and made of a molded relatively hard and rigid plastic, with electrical connectors (16) encapsulated therein. The core of the female receptacle (1) is of a one-piece construction and made of a relatively soft plastic, with electrical sockets (9) encapsulated therein. The female receptacle (1) also includes an external elongated tubular shell, or housing (11) made of a high density plastic material.

Description: Underwater electrical cables and electrical connectors cause major problems when they leak. Leakage is common due to the fact that such cables, and their connectors, commonly operate in subsurface environments or in near surface atmospheric environments characterized by extreme salt and humidity. Frequently, the male and female portions of these connectors are each constructed of a separate core and housing, which must be bonded together. Such connectors can have problems with leakage in the area of the bond between each core and housing. Additionally, the cores and housings of these connectors are often made of different materials. As a result, bonding at the interface between the different materials is imperfect and can cause water leakage problems. Moreover, when electrical contacts are embedded, either wholly or partially, within the male and female portions, water can penetrate the interface between the dissimilar materials of the electrical contacts and the male and female portions of the connector. For example, German Patent Publication DE-A-26 50 240 discloses electrical contact members embedded in both the male and female portions of an electrical connector. In both portions, any water or moisture that may be present prior to electrical assembly of the connector can pass along the interface between the respective electrical contacts and the surrounding insulating material of the connector portions. In a similar manner, British Patent Publication GB-A-2 131 633 discloses electrical contacts partially embedded in respective male and female portions of an electrical connector assembly. Neither of the above arrangements provide an electrical connector that is open-face waterproof, nor do the German or British publications disclose a structure or other means for sealing the interface between respective electrical contacts and the surrounding material in which the contacts are embedded. Thus, water or moisture can readily wick along the interface between the dissimilar materials and penetrate the connector and/or the multi-wire electrical cable assemblies attached to the connectors. The general object or the present invention is to provide an electrical connector which solves the water leakage problems described above and which can be utilized in marine seismic operations. Another object or the invention is to provide and electrical connector which is open-face waterproof. Still another object of the invention is to provide an electrical connector which can provide a water-tight connection even if connected while under water. SUMMARY OF THE INVENTION The present invention is directed to an open-face waterproof, underwater matable electrical connector which can be used in marine seismic operations. The electrical connector assembly comprises a male portion and a female portion. The male portion has a core with electrical contact members encapsulated therein. The electrical contact members encapsulated within the male portion are surrounded over a portion thereof with a sheath which is integrally formed with and of the same material as the core of the male portion. Each of the electrical contact members has a plurality of axially spaced and radially inwardly extending grooves arranged to prevent the passage of water between a respective contact member and the core or sheath material surrounding the contact member. The female portion has a body with sockets encapsulated therein and an electrical sleeve disposed in each of the sockets. The sockets in the female portion have at least one radially inwardly extending sealing rib for sealingly engaging the sheath portion of the electrical connectors in a substantially watertight manner and acting as a barrier to seepage of water into the interior of the sockets. In the preferred embodiment of the present invention, each of the electrical sleeves has a plurality of axially spaced and radially inwardly extending grooves arranged to prevent the passage of water between a respective sleeve and the body material surrounding the sleeve. The male and female portions of the connector are releasably engageable with one another to releasably maintain the sockets and the sheaths surrounding the electrical contact members in their substantially watertight sealing engagement. Use of a one-piece construction within the male portion and female portion of the electrical connector assembly eliminates an interface between two materials, obviates the shortcomings of the prior art, and enables the production of electrical connectors capable of operational advantages over the prior art but which are markedly simpler to make and less expensive. An additional feature of the invention is that each pin and socket connection is individually sealed. The female portion of the connector contains individual sealing ribs for each socket, whereas, if an electrical connector with a single O-ring design is not coupled in correct alignment, the O-ring will let water into the connector housing, which can cause problems with the electrical connection of some designs. With the present connector, a misaligned connection may allow water inside the housing, but the individual sealing ribs will act to maintain a good connection at each pin and socket. The above advantages, and numerous other features and advantages of the invention, will become more readily apparent upon a careful reading of the following detailed description, claims and drawings, wherein like numerals denote like parts in the several views, and wherein: BRIEF DESCRIPTION OF THE DRAWING The figure shows is a longitudinal cross-sectional view of the present invention. DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT As shown in the Figure, a waterproof electrical connector assembly 1 for underwater and/or marine environment usage in general is provided. The particular embodiment shown in the Figure is for a connector attachment at an underwater seismic data acquisition unit. The connector assembly includes a female receptacle 1, a mounting nut 2, and a male receptacle 3. The overall configuration of the female receptacle 1 includes a generally cylindrical inner member or body 4 that can be made, for example, of a suitable synthetic elastomer. The rear end of the inner member 4 is molded integrally with a stress relief device 5 which can include a conical-shaped series of spaced elastomer rings 6. The insulated conductor cable 7 passes through the stress relief device 5 and into, and through, the body member 4. At a location within the body member 4, the conductor wires 8 in the cable 7 are brought out and attached to conductive metal sleeves at the respective rear ends of a plurality of sockets 9. The sockets 9 are arranged in a certain pattern, such as five at 60 degrees around a center socket. The sockets 9 open to the outside of the front end surface 10 of the body member 4, the bottom socket position being empty so that the pins and sockets can be engaged in only one relative angular position. Another part of the connector assembly is an elongated tubular shell 11 which preferably is made of a high density plastic material. The shell 11 is rotatably mounted on the body member 4 and has a forward portion 12 that is internally threaded at 13. The shell 11 spans a substantial portion of the body member 4, and the bore 14 of the shell 11 is sized such that it can be easily rotated by hand relative to the body member 4. Longitudinal ribs can be provided on the shell 11 as an aid to turning. The overall configuration of the male receptacle 3 is also shown in the Figure. The male receptacle 3, which is configured in the present embodiment to be mounted to a sidewall of a data acquisition unit with mounting nut 2, includes a central body or core 15 and a tubular wall 17 which are mold formed around a plurality of connector pins 16. The core 15 and the tubular wall 17 are integrally formed in a one-piece construction, and are preferably manufactured of glass impregnated polyurethane. The connector pins 16 are elongated metal members with rounded ends and are arranged in the same pattern as the sockets 9. A portion of each connector pin 16 is covered by a sheath 18 which is formed integrally with the core 15 and the tubular wall 17, and made of the same material. Thus, the core 15, the tubular wall 17, and sheath 18 of the male receptacle 3 are of a one-piece construction. A conductor wire 19 is soldered to the rear side of each connector pin 16 to electrically connect the respective pins 16 to an electrical circuit. Core 15 has an end face 20 which is inwardly recessed from the open end 21 of the tubular wall 17 thus forming an interior space 22. In the preferred embodiment, the core 15 has two sets of threads 23, 24, formed externally thereof. Threads 23 match the internal threads 13 on the forward end portion of the shell 11. Threads 24 match with internal threads 28 in a mounting nut 2. The mounting nut 2 is used if the connector assembly is to be mounted in the sidewall panel of a data acquisition unit. If an in-line connector assembly is desired, the connector assembly can be modified in a manner known to those with skill in the art so as to eliminate the mounting nut 2. In the panel mount configuration shown in the Figure, the male receptacle 3 is made of rigid plastic because it is mounted to the panel of a data acquisition unit. In another embodiment, the core of the female receptacle 1 could be mounted to the data acquisition unit and would then be made of a relatively rigid plastic while the male receptacle 3 would be made of a relatively soft plastic. For an in-line connector, either core of the female receptacle 1 or the male receptacle 3 could be made of the relatively rigid plastic with the other receptacle being made of relatively soft plastic. As the threads 23 and 13 are progressively engaged by right hand rotation of the shell 11, the sockets 9 are forced to telescope over the connector pins 16 as the front portion and face 10 of the body 4 is advanced into the tubular wall 17, forcing water out of cavity 22, and a water-tight seal is achieved. When the threads 13 and 23 are made up hand tight, the front end surface 10 is up against the end face 20 of the core 15 of the male receptacle 3 and the interior face 25 of the shell 11 is up against the end face 26 of tubular wall 17. The sockets 9 have a particular configuration as shown in the Figure. Each socket 9 includes up to four axially spaced and inwardly extending sealing ribs 27 which are integrally molded as part of the body member 4. The inner diameter of each sealing rib 27 is smaller than the cross-sectional area of its respective connector pin sheath 18. Thus, when the connector pin 16 is inserted into its respective socket 9, the connector pin sheath 18 radially compresses the resilient sealing ribs 27 which then provide a seal effective to isolate each set of mating connector pin 16 and socket 9 from each other and from the surrounding environment, to provide a leak-proof connector. Upon mating, the distal portion of each connector pin 16 is encapsulated by the tubular shell 11 of the female receptacle 1. When the connector is assembled under water the presence of residual water between each connector pin 16 and its respective socket 9 will not cause short circuiting between the contact sets since the seal is also electrically insulating. The connector pins 16 also have a particular configuration as shown in the Figure. Each connector pin 16 has one or more axially spaced and radially inwardly extending grooves 29 machined into it. The plastic material of male receptacle 3 is preferably injection molded around the connector pins 16. As the plastic material cools immediately following the injection molding step some shrinkage occurs and the plastic fills in the grooves 29, thus creating a water barrier and making the male receptacle 3 open-face waterproof Similarly, the rear end of each socket 9 also has one or more axially spaced and radially inwardly extending grooves 30 machines into it. As with the injection molding of the male receptacle 3, as the core of the female receptacle 1 is injection molded, the plastic material cools and shrinkage occurs with the plastic filling in the grooves 30, making the female receptacle 1 open-face waterproof. In the preferred embodiment, the core 15, the tubular outer wall 17, and the connector pin sheath 18 of the male receptacle 3 is made of polyurethane, which may be glass impregnated polyurethane. However, any rigid non-hydroscopic plastic with good electrical properties could be used. Because the inner core 15, tubular wall 17, and connector pin sheath 18 are made of the same material they may be molded in one piece, whereby no voids are produced. When glass impregnated polyurethane is molded it sets up as a rather hard if not semi-rigid body. The glass imparts strength as well as rigidity to the body. In the event it is desired to increase the hardness of the housing to better withstand abrasion and/or harsh treatment during usage, the fiber-glass content may be increased or conversely, lowered. It is believed that a fiberglass content in the range of 15% to 65% by weight would generally accomplish the objects of the invention as described herein. The body 4 of the female receptacle 1 can be made of molded polyurethane material with a durometer of about 80, but modifications are possible and material substitutions permissible. Specifically, thermosetting plastic material could be used in place of thermoplastic for body 4. A greater or lesser durometer could be used as long as distortion is possible with manually applied insertion forces. The aforementioned materials are proposed by way of example for use in connection with the current invention. These materials, and any other constituting a substantial equivalent and appropriate for the purpose here intended may, when used in accordance with techniques recommended by the manufacturers, be used for molding, through injection or other appropriate techniques the male receptacle 3 and female receptacle 1 of the electrical connector hereof.

Claims: An electrical connector assembly for use in marine and corrosive environments, said electrical connector assembly comprising a connector body (4) and a connector core (15) configured to allow telescoping interaction together when assembled, said connector body (4) having a plurality of sockets (9) molded therein, each of said sockets (9) having an electrically conductive sleeve (31) disposed therein and at least one radially inwardly extending sealing rib (27) integrally formed on an internal wall surface of each of said sockets (9), and the connector core (15) having a plurality of electrical contact members (16) at least partially encapsulated therein, each of the electrical contact members (16) having a predetermined length that is surrounded by a sheath (18) extending along a portion of said length and integrally formed with said core (15), said contact members (16) being arranged for engagement with a predetermined one of said electrical sleeves (31) disposed in a corresponding socket (9) molded in said body (4) whereby said at least one sealing rib (27) cooperates with a respective sheath (18) surrounding a portion of each of said electrical contact members (16) to form a waterproof seal between each respective socket (9) and sheath (18) solely in response to inserting the contact members (16) into electrical contacting engagement with the sleeves (31), said electrical connector assembly being characterized by said connector core (15) having an integrally formed tubular wall portion (17) that is closed at one end (20) and open at the other end (21) and said electrical contact members (16) having a plurality of axially spaced and radially inwardly extending grooves (29) with the connector core (15) being mold formed around the electrical contact members (16) and filling the grooves (29) to prevent the passage of water between a respective contact member (16) and the sheath (18) surrounding a portion of the length of the contact member (16). The electrical connector assembly of claim 1, wherein said electrical sleeve (31) disposed in each of said sockets (9) has a plurality of axially spaced and radially inwardly extending grooves (30) arranged to prevent the passage of water between the sleeve (31) and the internal wall surface of said socket (9). The electrical connector assembly of claim 1, wherein the connector body (4) is formed of a relatively soft plastic material and the connector core (15) is formed of a relatively hard and rigid plastic material. The electrical connector assembly of claim 3, wherein the relatively soft plastic material from which the connector body (4) is formed is polyurethane. The electrical connector assembly of claim 3, wherein the relatively hard and rigid plastic material from which the connector core (15) is formed is fiberglass impregnated polyurethane. The electrical connector assembly of claim 1, wherein said electrical connector assembly is open-face waterproof. The electrical connector assembly of claim 1, wherein said connector core (15) forms a male plug portion of said connector assembly and said connector body (4) forms a female receptacle portion of said connector assembly. The electrical connector assembly of claim 1, wherein the axially spaced and radially inwardly extending grooves (29) of said electrical contact members (16) disposed in said core (15) are filled with the same material as said core (15) whereby said contact member grooves (29) and said core material cooperate to form a waterproof seal between said contact members (16) and said core (15). The electrical connector assembly of claim 2, wherein the axially spaced and radially inwardly extending grooves (30) of said electrical sleeves (31) disposed in each of the sockets (9) of the connector body (4) are filled with the same material as said body (4) whereby said sleeve grooves (30) and said body material cooperate to form a waterproof seal between said sleeves (31) and said body (4). The electrical connector assembly of claim 1, wherein said connector assembly includes a shell (11) having a plurality of internal threads (13) formed adjacent one end thereof and said connector core (15) has a plurality of external threads (23) disposed on an outer circumferential surface, said shell (11) being disposed in substantially surrounding and independently rotatable relationship with respect to said connector body (4), and said electrical contact members (16) of the connector core (15) being drawn into and maintained in electrical contact with the sleeves (31) of the connector body (4) in response to threadably engaging the internal threads (13) of the shell (11) with the external threads (23) of the connector core (15).

Inventors: WOOD RICHARD G, WOOD, RICHARD G.
Applicants: INPUT OUTPUT INC, INPUT/OUTPUT, INC.
Application year: 1994
Main classification: H01R13
IPC codes: H01R13